Digital Twin: Transparency and control for complex systems

Why digital twins are crucial for modern systems development

ITQ develops and implements digital twins for highly complex machinery and plant. In modern systems, virtual models help to understand functions, interrelationships and behaviour at an early stage. The digital twin thus provides a solid foundation for the development, coordination and validation of complex systems.

What is crucial here is not just the simulation itself, but the use of the model throughout the entire life cycle. As a core element of virtual engineering, the digital twin supports the early assessment of concept, function and quality, and creates transparency across disciplines.

Your benefits at a glance:

Early evaluation of concepts and functions
Faster and more cost-effective testing
Transparency regarding system behaviour and interrelationships
Greater coordination between disciplines
The basis for virtual engineering throughout the entire life cycle
Virtual commissioning, even before a physical prototype exists

Finding the right solution together

Your personal contact for software engineering will be happy to advise you on your specific enquiry.

Get in touch now for a no-obligation consultation.

Simon Freutel

ITQ Branch Manager, North Rhine-Westphalia

„The biggest challenge is not choosing a technology, but making a well-informed assessment of its impact on the system as a whole.“

Virtual models for efficient engineering

The development of modern machinery is becoming increasingly complex. Errors often arise as early as the design phase because functions are inadequately specified or not presented clearly. They usually only come to light during commissioning and must then be rectified on the actual prototype. At the same time, demands regarding quality, product variety and development time are on the rise.

This is precisely where the digital twin comes into play: systems are modelled virtually at an early stage and their functions are evaluated whilst they are still being developed. Simulations, digital models and functional demonstrators make it possible to compare concepts, implement changes in a controlled manner and coordinate systems across disciplines.

The model can subsequently be used for virtual commissioning. Software testing takes place even before the prototype is built, which shortens the project duration and significantly improves software quality.

Digital Twins in the engineering process

Typical challenges within a company:

Poorly coordinated functions and mechatronic structures
Software development begins without adequate testing facilities on real hardware
Late fault detection during development and testing
High costs due to late implementation of real-world safeguards
A lack of transparency regarding system behaviour – particularly in the event of faults
Complex coordination between disciplines

Only through the use of virtual models and simulation can the development of complex systems be made efficient and manageable.

Services relating to digital twins and simulation

ITQ supports companies in the design and implementation of digital twins – from modelling through to integration into the development process and virtual commissioning.

An overview of our services

Analysis of the requirements for digital twins and simulation
Selection of suitable simulation and modelling tools
Development of system models and component libraries
Integration into existing engineering processes
Design and development of HiL laboratory environments

Technological expertise

Procedures for Digital Twin Projects

The introduction of a digital twin requires a structured approach. ITQ uses model-based methods to integrate simulation and virtual validation into the development process at an early stage.

Project phases

Analysis of requirements

Definition of the objectives and requirements for the digital twin and the simulation.

Selection of suitable tools

Evaluation and selection of tools for modelling, simulation and testing.

Structure of the system models

Development of simulation models and mechatronic components.

Integration into the development process

Integration of the models into development, coordination and validation.

Use throughout the life cycle

Use of the digital twin not just for a single process step. Utilisation of models and libraries throughout the entire process to support seamless information transfer.

Digital Twins in Practice

Sector: Logistics, Mechanical Engineering

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Further ITQ solutions

The services described form part of ITQ’s comprehensive service portfolio. ITQ combines technological expertise, a methodical approach and a deep understanding of processes to deliver sustainable solutions throughout the entire life cycle.

FAQs – Digital Twins

What is a digital twin?

A digital twin is a virtual representation of a real-world system that simulates its behaviour, states and processes, making them amenable to analysis.

What is a digital twin used for?

It is used for the simulation, optimisation and monitoring of machinery and plant throughout their entire life cycle.

What are the benefits of a digital twin?

It enables early testing, reduces risks and improves the basis for decision-making through realistic simulations.

How does a digital twin differ from simulations?

A digital twin is permanently connected to the real-world system and continuously reflects its state, whereas simulations are often carried out in isolation.

Any further questions ...

When is it worth using a digital twin?

This is particularly true of complex systems where testing in a live environment is time-consuming or high-risk.

How does ITQ support the development of digital twins?

ITQ develops simulation-based models and integrates them into existing systems to enable well-founded analyses and optimisations.